System of Construction Elements for Jointless Erection of Building Walls

The subject of the invention is a system of construction elements for jointless erection and dry erection of building walls without the use of mortars or adhesives, suitable for residential and industrial construction.

A system of construction elements for dry erection of buildings is known from the Polish patent No. PL220759, featuring profiled lugs for mating during assembly. It consists of modular construction elements for erecting a wall, ceiling and roof, with a module comprising two elements set adjacent by their sides connected by a third element and forming an interlocking connection, with the profiled lugs of the construction elements having two lateral mating surfaces, guiding and interlocking, inclined at specific angles, angles α and β, with angle α in the range of 40°-50°, and angle β in the range of 6°-12°, with the said angles set respectively between a line perpendicular to the top or bottom surface of the lug and the guiding or interlocking surface.

A wall construction system consisting of a plurality of interlocking concrete blocks is also known from the American patent No. U.S. Ser. No. 10/941,567. The interlocking blocks include one or more spreader blocks, corner blocks and half blocks. Blocks in the system include top and end shear lugs, and bottom and end grooves. The bottom grooves fit inside the top lugs of the blocks in the lower course of stacked blocks. Corner blocks ensure means to form a corner and rotate the direction of the block course by 90°, The interlocking elements of the blocks allow blocks to be laid dry in successive layers to erect a wall or multi-wall structure. When stacked on top of each other in successive courses, the top and end lugs of each block lock with complementary grooves in blocks that are underlying, overlying and adjacent, in this manner allowing quick self-alignment and interlocking of the blocks when stacked.

Solutions known in the state of the art, despite using techniques used for seamless joining of elements, do not eliminate, so-called, thermal bridges occurring in places where elements are joined, on vertical edges or in wall corners.

The thermal insulation of a building is the second most important issue when selecting its construction material, with the first being ensuring appropriate strength properties. Achieving appropriate thermal conductivity on the external walls of a building retains the thermal energy supplied to heat the interior of the building. Therefore, the objective of the invention was to develop a system for jointless erection of building walls, in which the elements will be connected by system-based geometric and technical solutions for mating individual elements closing thermal bridges of the erected building walls. In the solution according to the invention, the basic assumption was to eliminate thermal bridges and in this manner ensure additional tightness of building wall partitions and limit the use of bonding and insulating materials, as well as improve warmth in constructed buildings.

A system of construction elements for jointless erection of building walls, consisting of center, corner and edge blocks, with each block having a cuboid shape with profiled mating means in the form of lugs and recesses matching adjacent blocks at the points of their locking, characterized in that the interlocking means in the center, corner and edge blocks are located on each horizontal and vertical mating surface, wherein:

Preferably, the lugs on the vertical mating surfaces have a trapezoidal cross-section.

Preferably, the lugs on the horizontal top surfaces have chamfered edges.

Preferably, the center block, or the corner block, or the edge block have at least one utility opening.

Preferably, the center block has a half form.

Preferably, the system includes lintels made of edge blocks, a rectangular beam and top blocks.

Preferably, the top block includes on the horizontal bottom surface a rectangular recess adapted for interlocking with the lugs of the edge block.

Preferably, the vertical mating surface of the top block, along the entire height, has at least one lug or at least one recess shaped accordingly to the lugs, and includes undercuts

Preferably, the top block on the horizontal top surface has mating means in the form of lugs shaped as two flattened cuboids, arranged symmetrically and connected by a crosspiece.

Preferably, the beam has perpendicularly bent ends.

The solution according to the invention makes it possible to close thermal bridges at joints of all mating planes of construction elements, including lintel beams, in order to obtain full insulation of constructed building walls, while maintaining the simplicity and convenience of a jointless connection, which was confirmed in the tests presented further in the description. The solution according to the invention disposes of a unique system of connecting individual elements based on specially profiled geometric recesses and lugs. System elements are easy to install thanks so-called dry joining, without the use of wet mortars, adhesives and other products, and the implemented mating. System elements can be installed by unskilled workers working only under supervision or by future users of the building. In addition, the system according to the invention ensures easy transport and does not require heavy specialized equipment for installation, reducing construction time and significantly lowering financial outlays. Employing the system according to the invention allows eco-friendly and energy-saving buildings to be designed.

In the first embodiment, the system of construction elements for jointless erection of building walls consists of elements in the form of center blocks, corner blocksand edge blocks, and may optionally include elements meant for creating a lintel in the form of adapted edge blocks, a cuboid beamand top blocks. The center blockhas a cuboid shape with profiled mating means located on each horizontal and vertical mating surface, wherein the horizontal top surface.has mating means in the form of lugs.shaped as two flattened cuboids with chamfered edges, arranged symmetrically on the horizontal top surface and connected by a crosspiece.., as shown in. The lugs.have a height of 1/10 of the height of the entire blockand a surface area that equals ⅔ of the horizontal top surface of the entire block, while the chamfer on the edges has an angle of 45°. In other embodiments they may have a chamfer angle of 40° to 60°. In other embodiments, the lugs.may not have chamfers, as shown in. On the horizontal bottom surface., the center blockcontains a cuboid recess.adapted for interlocking with lugs.or.or.on the top surface., or.or.of the center blocks, or the corner blocks, or the edge blocks. The recess.has a surface area equal to 0.83 of the horizontal bottom surface area.of the block. On the vertical mating surfaces., the center blockhas along its entire height a lug.with a trapezoidal cross-section and an appropriate recess.with a shape adapted to the lug., and additionally includes an undercut.appropriate in shape for interlocking with a crosspiece or lug.or.on the top surface.or.or.of center blocksor corner blocks or edge blocks. The extreme outside surface of the lug.corresponds to 1/20 of the side surface area of the block, while the sides forming the trapezoidal lug.are inclined in relation to its base at an angle of 45° over a length of 1 cm.

In other embodiments, the center blockhas, on each of the vertical mating surfaces., along the entire height, lugs.with a trapezoidal cross-section or, on each of the vertical mating surfaces., along the entire height, recesses.of a shape adapted to the lug.or.or.on adjacent center blocks, corner blocksor edge blocks, as shown inand

In other embodiments, the center blockmay contain utility through openingsof a round or rectangular shape, made within lugs.. Utility openingsare intended for routing cables or systems, as shown inand

The center blockmay also be made in the form of a half block, in which mating means are made on the horizontal top surface.in the form of a lug.of a flattened cuboid shape, as shown inand

The corner blockhas a cuboid shape with profiled mating means placed on each horizontal and vertical mating surface, wherein the horizontal top surface.has mating means in the form of lugs.shaped as flattened cuboids with chamfered edges and a lug., as shown in. In other embodiments, lugs.may not have chamfers, as shown in. On the horizontal bottom surface.it contains a rectangular recess.adapted for connecting to lugs.or.or.located on the top surface.or.or.of center blocksor corner blocksor edge blocks. On vertical mating surfaces.or., the corner blockhas, along the entire height of the block, a lug.with a trapezoidal cross-section or, respectively, a recess.of a shape adapted to the lug.or.or.on adjacent center blocks, corner blocksor edge blocks. On the vertical mating surfaces.or., the corner blockcontains undercuts.adapted in shape to connect to a crosspiece..or lug.or.on the top surface.or.or.of center blocksor corner blocksor edge blocks.

In other embodiments, the corner blockhas, on each of the vertical mating surfaces.or., along the entire height, lugs.with a trapezoidal cross-section or, on each of the vertical mating surfaces.or., along the entire height, recesses.with a shape adapted to the lug.or.or.on adjacent center blocks, corner blocksor edge blocks, as shown inand

In other variants, the corner blockhas, on each of the vertical mating surfaces.and.and.′ or.and.′ and.and.′, along the entire height of the block, a recess.of a shape adapted to the lug.or.or.on the adjacent center blocks, corner blocksor edge blocks. On the vertical mating surfaces.or.′ or.or.′, the corner blockcontains undercuts.adapted in shape for connecting to the crosspiece..or lug.or.on the top surface.or.or.of center blocksor corner blocksor edge blocks, as shown inand

In other embodiments, the corner blockmay contain utility through openingsof a round or rectangular shape, made within lugs.. Utility openingsare intended for routing cables or systems, as shown inand

The edge blockhas a cuboid shape with profiled mating means placed on each horizontal and vertical mating surface, wherein the horizontal top surface.has mating means in the form of the lug.shaped as a flattened cuboid with protrusion..

In other embodiments, the lug.may not have a chamfer. On the horizontal bottom surface.it contains a rectangular recess.adapted for connecting to lugs.or.or.located on the top surface.or.or.of center blocksor corner blocksor edge blocks. On vertical mating surface.the corner blockhas, along the entire height of the block, a lug.with a trapezoidal cross-section or, respectively, a recess.of a shape adapted to the lug.or.on adjacent center blocksor corner blocks. On the vertical mating surfaces.the edge blockincludes an undercut.adapted in shape for connecting with the crosspiece..or lug.or.on the upper surface.or.or.of the center blocksor the corner blocksor the edge blocks, as shown inand

In other embodiments, the edge blockhas on the horizontal top surface.mating means in the form of two lugs.of a flattened cuboid shape, whose protrusions.are interlocked to form a crosspiece. On the vertical mating surface.and the parallel vertical surface, the edge blockincludes an undercut.adapted in shape for connecting with the crosspiece..or lug.or.on the top surface.or.or.of the center blocksor the corner blocksor the edge blocks, as shown inand

As an option, the system may include elements to make a lintel in the form of an adapted edge block, a cuboid beamand top blocks.

The edge blockmay also be made in a variant adapted for constructing a lintel, in which it has a cuboid shape with profiled mating means located on each horizontal and vertical mating surface, wherein the horizontal top surface.has mating means in the form of the lug., in the shape of a flattened cuboid with chamfered edges and with the protrusion.. In other embodiments, the edge blockin the variant for lintels may feature an additional lug.on the horizontal top surface. On the horizontal bottom surface.it contains a cuboid recess.adapted for fixing to lugs.or.or.on the top surface.or.or.of the center blocksor the corner blocksor the edge blocks. On the vertical mating surface., the edge block has, along the entire height of the block, a lug.with a trapezoidal cross-section or, respectively, a recess.with a shape adapted to the lug.or.on adjacent center blocksor corner blocks. On the vertical mating surface.and on the parallel vertical surface, the edge blockhas an undercut.adapted in shape for connecting to the crosspiece..or protrusion.or.on the top surface.or.or.of center blocksor corner blocksor edge blocks, as shown inand

The lintel beamhas the shape of a flattened cuboid with dimensions determined on the basis of structure strength calculations. In other embodiments, the beammay have perpendicularly bent ends and form a U shape in a longitudinal section, as shown inand

The top blockhas a cuboid shape with profiled mating means located on the horizontal and vertical mating surfaces, wherein the horizontal bottom surface.contains mating means in the form of a cuboid recess.adapted for connecting with lugs.of the edge block. The vertical mating surface.of the top blockhas, along the entire height of the block, a lug.with a trapezoidal cross-section and, respectively, a recess.with a shape adapted to the lug.and contains undercuts.adapted for connecting with the lintel beamand with the edge blocks. The horizontal top surface.of the top blockmay be flat or, in another variant, may be equipped with lugs.with a shape of two flattened cuboids with chamfered edges, arranged symmetrically and connected by a crosspiece.., as shown inand

In another embodiment, the system of construction elements for jointless erection of building walls consists of elements in the form of center blocks, corner blocksand edge blocks, and may optionally include elements meant for creating a lintel in the form of adapted edge blocks, a cuboid beamand top blocks. The center blockhas a cuboid shape with profiled mating means located on each horizontal and vertical mating surface, wherein the horizontal top surface.has mating means in the form of lugs.shaped as two flattened cuboid bodies, arranged symmetrically and connected by a crosspiece.., as shown in. Lugs.have a height of 1/10 of the height of the entire blockand a surface area that equals ⅔ of the horizontal top surface.of the entire block. In other embodiments, the lug.may have chamfered edges, with the chamfer within the 40° to 60° range. On the horizontal bottom surface.the center blockcontains a rectangular recess.adapted for connecting to lugs.or.or.located on the top surface.or.or.of center blocksor corner blocksor edge blocks. On the vertical mating surfaces., along the entire height, the center blockhas two lugs.with chamfered vertical edges and respectively, two recesses.of a shape adapted to the lugs.and additionally includes an undercut.adapted in shape to the connection with the crosspiece..or lug.or.on the top surface.or.or.of center blocksor corner blocksor edge blocks. The sum of the outermost external surface of lugs.corresponds to 1/20 of the side surface area of block.

In other variants, the center blockhas, on each of the vertical mating surfaces., along the entire height, two lugs.with chamfered vertical edges or has, on each of the vertical mating surfaces., along the entire height, two recesses.with a shape matching lugs.or.or.on adjacent central blocks, corner blocksor edge blocks, as shown inand

The center blockmay also be made in the form of a half block, in which mating means are made on the horizontal top surface.in the form of lugs.with a flattened cuboid shape, as shown inand

The corner blockhas a cuboid shape with profiled mating means located on each horizontal and vertical mating surface, wherein on the horizontal top surface.it has mating means in the form of lugs.in the shape of flattened cuboid bodies with chamfered edges and the protrusion., while the bottom horizontal surface.contains a cuboid recess.adapted for mating with lugs.. or.or.located on the top surface.or.or.of center blocksor corner blocksor edge blocks. On vertical mating surfaces.or., the corner blockhas, along the entire height of the block, two lugs.with chamfered vertical edges or, respectively, two recesses.with a shape adapted to lugs.or.or.on adjacent center blocksor corner blocksor edge blocks. The vertical mating surfaces.or.of the corner blockcontain undercuts.adapted in shape to mate with the crosspiece..or the protrusion.or.on the top surface.or.or.of center blocksor corner blocksor edge blocks, as shown inand

In other variants, the corner blockhas, on each of the vertical mating surfaces.or., along the entire height, two lugs.with chamfered vertical edges or, on each of the vertical mating surfaces.or., along its entire height, two recesses.with a shape adapted to lugs.or.or.on the adjacent center blocks, corner blocksor edge blocks, as shown inand

The edge blockhas a cuboid shape with profiled mating means placed on each horizontal and vertical mating surface, wherein the horizontal top surface.has mating means in the form of the lug., in the shape of a flattened cuboid with the protrusion.. In other embodiments, the lugs.may have chamfered edges. On the horizontal bottom surface.it contains a cuboid recess.adapted for mating with protrusions.or.or.located on the top surface.or.or.of the center blocksor the corner blocksor the edge blocks. On the vertical mating surface.the corner blockhas, along the entire height of the block, two lugs.with chamfered vertical edges or, respectively, two recesses.of a shape adapted to the lug.or.on adjacent center blocksor corner blocks. On the vertical mating surfaces.the edge blockincludes an undercut.adapted in shape for connecting with the crosspiece..or lug.or.on the upper surface.or.or.of the center blocksor the corner blocksor the edge blocks, as shown inand

As an option, the system may include elements to make a lintel in the form of an adapted edge block, a cuboid beamand top blocks.

The edge blockin the variant adapted for making a lintel may also have a cuboid shape with profiled mating means located on each horizontal and vertical mating surface, wherein the horizontal top surface.has mating means in the form of the lug., in the shape of a flattened cuboid with chamfered edges and with the protrusion..

On the horizontal bottom surface.it contains a cuboid recess.adapted for mating with protrusions.or.or.located on the top surface.or.or.of the center blocksor the corner blocksor the edge blocks. On the vertical mating surface.the corner blockhas, along the entire height of the block, two protrusions.with chamfered vertical edges or, respectively, two recesses.of a shape adapted to the lugs.or.on adjacent center blocksor corner blocks. On the vertical mating surface.and the parallel vertical surface, the edge blockincludes an undercut.adapted in shape for connecting with the crosspiece..or lug.or.on the top surface.or.or.of the center blocksor the corner blocksor the edge blocks, as shown inand

The lintel beamhas the shape of a flattened cuboid with its size depending on strength parameters, while the beam width remains constant and corresponds to the undercut.in the upper block, as shown in

The top blockhas a cuboid shape with profiled mating means located on the horizontal and vertical mating surfaces, wherein the horizontal bottom surface.contains mating means in the form of a cuboid recess.adapted for connecting with the lugs.of the edge block. The vertical mating surface.of the top blockhas, along the entire height of the block, two lugs.with chamfered vertical edges and, respectively, two recesses.with a shape adapted to the lug.and containing undercuts.adapted for connecting with the lintel beamand with the edge blocks.

The horizontal top surface.of the top blockmay be flat or, in another variant, may be equipped with lugs.with a shape of two flattened cuboids with chamfered edges, arranged symmetrically and connected by a crosspiece.., as shown inand

The system of elements for dry erection of building walls has been subjected to thermal insulation tests aimed at confirming adequate thermal conductivity of external building walls and elimination of

Calculations of thermal transfer were performed based on the PN-EN 12831:2006 standard.

Heat transfer from a heated space to the surroundings through an external non-insulated wall made of 10 cm thick hollow bricks.

Heat transfer coefficient corrected for losses caused by linear thermal bridges:

To determine the heat loss coefficient of a wall, it is necessary to determine its surface area and then multiply it by the heat transfer coefficient corrected for thermal bridges.